Cavity formed tube for a grill guard

ABSTRACT

A grill guard for a motor vehicle comprises a plurality of horizontal formed tubes and a plurality of vertically extending connecting members for connecting together the plurality of tubes so as to define the grill guard. The end of each formed tube is curved, and is provided with a cap member that is integral with the formed tube. The cap member serves to substantially cover the circular aperture at the curved end of the tube, so as to provide a relatively more attractive and safer grill guard.

BACKGROUND OF THE INVENTION

[0001] This invention relates to a grill guard for the grill of a motorvehicle, and in particular to a cavity formed tube for the grill guardand to a method of manufacturing this formed tube.

[0002] Grill guards typically comprise a plurality of horizontal roundtubes that are joined together, with the grill guard then being fittedto a front end of the vehicle.

[0003] Typically, however, the ends of each tube are left unfinished andopen-ended, so as to define circular apertures at each end. Thisstructure is thus relatively unattractive, and the burred apertures arealso potentially dangerous with a person's hand and/or clothing quiteeasily being caught on, and torn by, these ends.

[0004] It is therefore desirable to provide a grill guard that addressesthe abovementioned problems.

SUMMARY OF THE INVENTION

[0005] According to a first aspect of the invention there is provided acavity formed tube, the formed tube having a curved end that defines anend aperture, wherein the tube includes a cap member that is integralwith the formed tube, the integral cap member being arranged tosubstantially cover the end aperture of the curved end of the tube.

[0006] Preferably, an opening is defined between the integral cap memberand the tube.

[0007] Typically, the formed tube forms part of a grill guard for amotor vehicle, the grill guard comprising a plurality of formed tubesand connecting means for connecting together the plurality of formedtubes so as to define the grill guard.

[0008] According to a second aspect of the invention there is provided amethod of manufacturing a cavity formed tube, the method comprising thesteps of:

[0009] providing a tube;

[0010] pressing the tube so as to define a curved end; and

[0011] cropping the curved end so as to define a cap member that isintegral with the formed tube, the integral cap member being arranged tosubstantially cover the curved end of the tube.

[0012] Preferably, the method further includes the step of pressing thecurved end so as to define an opening therein.

[0013] According to a third aspect of the invention there is provided agrill guard for a motor vehicle, the grill guard comprising:

[0014] a plurality of tubes, each tube having a curved end that definesan end aperture, with each tube further including a cap member that isintegral with the tube, wherein the integral cap member is arranged tosubstantially cover the end aperture of the curved end of the tube; and

[0015] connecting means for connecting together the plurality of formedtubes so as to define the grill guard.

[0016] Typically, an opening is defined between the integral cap memberand the tube.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017]FIG. 1 shows a front view of a grill guard comprising a pluralityof formed tubes according to the invention;

[0018]FIG. 2 shows a close-up perspective view of an end of one of theformed tubes of the grill guard shown in FIG. 1;

[0019]FIG. 3 shows a front view of a pressing tool that is used in themanufacturing of the formed tube of the invention;

[0020]FIG. 4 shows a front view of a cropping tool that is used in themanufacturing of the formed tube of the invention; and

[0021]FIG. 5 shows a side view of a further pressing tool that is usedto finalise the formed tube of the invention.

DESCRIPTION OF AN EMBODIMENT

[0022] Referring to FIGS. 1 and 2, a grill guard 10 for a motor vehiclecomprises a plurality of horizontal formed tubes 12A to 12J and fourvertically extending connecting members 14A to 14D for connectingtogether the plurality of tubes 12A to 12J so as to define the grillguard 10.

[0023] The end 16 of each formed tube 12A to 12J, as can be clearly seenin FIG. 2, is curved, and is provided with a cap member 18 that isintegral with the formed tube. The cap member 18 serves to substantiallycover the circular aperture at the curved end of the tube.

[0024] The manufacturing of the curved end of each formed tube will nowbe described with reference to FIGS. 3 to 5.

[0025] A stainless steel tube 20 is first provided, and is fed to ahydraulic pressing tool 22. The pressing tool 22 comprises a pair ofcomplemental pressing plates 24 and 26 that are arranged to press andflatten the formed tube 20 so as to define a pair of curved ends 28 and30. The resulting, flattened tube 32 is shown in FIG. 4, with the curvedends 28 and 30 being clearly shown. The radius of curvature of eachcurved end 28 and 30 is in the region of 1¼ inch (31.75 mm).

[0026] The tube 32 is then mounted to a hydraulic cropping machine 34.The cropping machine 34 comprises a cutting element 36 that is arrangedto sever the curved ends 28 and 30 of the formed tube 32 from theflattened portion 38. This cropping process results in a curved end thatdefines the cap member 18 that is integral with the formed tube 32, forsubstantially covering the curved end of the formed tube.

[0027] The resulting covered, curved end 40 of the formed tube 32 isthen fitted to a further pressing tool 42. The tool 42 comprises a pairof pressing plates 44 and 46 that press the sides of the curved end 40so as to force the integral cap member 18 away slightly from the curvedend 40, thereby defining an opening 48. The opening 48 assists inelectro-polishing the formed tube 32, with, in particular, the opening48 allowing solvent to flow through the tube 32 during theelectro-polishing process.

[0028] The present invention thus provides a formed tube having a curvedend that includes an integral cap member, which can be used to form afar more attractive and safer grill guard.

I claim:
 1. A cavity formed tube, the formed tube having a curved endthat defines an end aperture, wherein the tube includes a cap memberthat is integral with the formed tube, the integral cap member beingarranged to substantially cover the end aperture of the curved end ofthe tube.
 2. A cavity formed tube according to claim 1, wherein anopening is defined between the integral cap member and the tube.
 3. Acavity formed tube according to claim 1, wherein the formed tube formspart of a grill guard for a motor vehicle, the grill guard comprising aplurality of formed tubes and connecting means for connecting togetherthe plurality of formed tubes so as to define the grill guard.
 4. Amethod of manufacturing a cavity formed tube, the method comprising thesteps of: providing a tube; pressing the tube so as to define a curvedend; and cropping the curved end so as to define a cap member that isintegral with the formed tube, the integral cap member being arranged tosubstantially cover the curved end of the tube.
 5. A method ofmanufacturing a cavity formed tube according to claim 4, wherein themethod further includes the step of pressing the curved end so as todefine an opening therein.
 6. A grill guard for a motor vehicle, thegrill guard comprising: a plurality of tubes, each tube having a curvedend that defines an end aperture, with each tube further including a capmember that is integral with the tube, wherein the integral cap memberis arranged to substantially cover the end aperture of the curved end ofthe tube; and connecting means for connecting together the plurality offormed tubes so as to define the grill guard.
 7. A grill guard accordingto claim 6, wherein an opening is defined between the integral capmember and the tube.